Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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The present invention relates to a method for making a non-
woven pile web from differently coloured pile yarns lying side by
:. side and being arranged so as to form a colour-figuration and
being adhered perpendicularly in a sub-layerO
: It is known from UOS. Patent 3,558,411 (GoBo Patent 101470628)
to make an endless strip or web of differently colouxed parts
laid side-by-side in the sequence of the desired colour-figuration
and by folding said strip or web in zig zag manner in the correct
sequence and positioning the folded parts on top of or next to
each other and joining them, a block i.~ formed, in which the de-
sired colour-figuration is built up by the different colour-changes
of the folded layers and by subsequently cutting off layers from
: the thickness of said block, its thickness being equal to the width
of the web or strip, webs are obtained which show the desired
colour-figuration in their pile-layerO
.~cc~ording to another method of ~id Patent the endless webs
which are formed from yarn end portions lying side by side and being
cross-connected to each other, are cut off and a number of narrow
pile strips, each one of which either being folded in zig zag
manner and the folded layers being joined to a pile web or each
pile strip being wound on a cylinder drum 90 that the windings
form a tube, which is subsequently cut open and unfolded to form a
web of the desired colour-figurationO
The disadvantage of the known method i9 that differently
coloured pre-dyed yarns have to be used which are arranged by a
jacquard device according to the sequence of the figurationsO With
a 7--colour-figuration, for a ~ingle row of yarn having a width
of eOgO 5 metres in which 2,000 piles are present side by side,
; 14,000 thread cones are requiredO With the connected spare cones
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for a single row one needs 28,000 thread conesO Two row~, which
are manufactured continuously in said device according to the
invention, would require 56,000 yarn cones, which means a huge
stock and high investment costs, and the coloured yarns are subject
to become left-overs which are not used anymore in other colour-
figurationsO
The disadvantage of the known method, iOeO to wind each pile
strip on a cylinder drum, consists in that with a view to suffi-
cient production, a cylinder must be used for each pile strip,
said cylinder having a circumference of 5 metres, which means that
a large number of cylinders must be used as a consequence of which
: the device becomes e~pensive and, in addition, correct positioning
of the various colour-changes of the windings in view of the build-
up of the desired colour-figuration causes considerable difficultiesO
The disadvantage of cutting webs from stacked pile webs to
form a block consists in that it is not possible to cut said webs
when they must have the length of a roll of carpet web having a
width of e.gO 5 metres and a length of 50 metres, particularly
when the block, for production purposes, has a thickness of 50
carpet webs or more~
. In order to prevent said difficulties the method according
to the invention is characterized in that simultaneously two rows
of differently coloured yarn end portions having a length equal to
:~ a multiple of the desired pile height are arranged in the sequence
of the desired colour-figuration, between which in cross-direction
and at a mutual spacing of two times the desired pile height a
number of threads extending parallel to each other and disposed
in series of two and having been impregnated with thermoplastic
or latex paste are pressed and joined so as to form a continuous,
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multi-coloured web, subsequently the multicoloured web i5 cut
in the direction parallel to the impregnated threads and between
the threads of each pair of impregnated threads into a number of
strips, and the next sections of each individual strip having a
length being e~ual to the desired width of the carpet web to be
made and the width of which being equal to twice the desired pile
height of said web to be made and are stacked and mutually con-
nected on both edges along the adhered, impregnated threads with
a number of threads and/or a backing layer being provided with a
thermoplastic or latex pasteO
The above indicated disadvantage of the large cylindrical drums
to be used for winding up the obtained product is removed when
the above method is usedO Moreover it is possible to make a non
woven pile w0b with cut piles or with looped pilesO
The method for making webs with cut pile is characterized in that
the strip sections being mutually connected along both side edges
subsequently are cut in a direction parallel to said side edges
in such a manner that two pile webs are obtained with single pile
heightO
The method for making webs with looped pile i8 characterized in
that before stacking each of the strip sections is folded into
the shape of a V and subsequentl~ the folded strip sections are
stacked and are mutually connected on the side on which the im-
pregnated thread~ are presentO
The present invention is also related to a device for per-
forming the above indicated methodO Said device being characteriz-
, ed in that it comprises means for feeding a series of pile forming
yarns having a length equal to a multiple of the desired pile
height, means for feeding in cross direction to said yarns and
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at a mutual distance equal to twice the desired pile height pairs
of threads ext~nding parallel to each other and being provided
with adhesive means to connect said yarns and said thread~, means
to cut the formed web parallel ts the pairs of threads and between
the threads of each pair, means to stack the obtained strips and
means to mutually connect the stacked strips along the side having
~ the threads being provided with adhe~iveO
:. For making a pile web with cut pile it is preferred that
means are provided to cut the stacked strip sections being mutually
connected along both sides in a direction parallel to said sidesO
; For making a pile web with looped pile it is preferred that
means are present to fold into the shape of a V the strip sections
before stacking them.
A simple embodiment is obtained when the means for feeding the
: series of pile yarns is formed by gripping means each having a
length equal to the desired width of the pile web, and it is pre-
ferred that the gripping means are present in pairs~
A simple ~eans is provided to connect the yarns and threadsO
Said means is characterized in that it comprises a press means
. 20 to which are fed continuous threads being provided with adhesive
:. and ever over a length equal 20 to the desired width of the web
and to which pile yarns are fed by the gripping means, said press
means being provided at the feed-side for the yarns with a cutting
means for cutting the yarns after pressing the yarns and threads
' togetherO
. .
If the device according to this invention is used when the
carpet and the figuration are not built up of more than three
different colours with which the yarns are coloured continuously
depending on the demand, a 5 metre width carpet web with 2,000
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piles in cross section, requires 3 x 2,000 cone-~ = 6,ooo yarn
cones for each rowJ iOeO 12,000 yarn cones, divided over three
~ colours, for two rows are fed simultaneouslyO
: Compared with the known device this number of cones is a great
savingO
A further simplification of the known d0vice is characterized
in that a jacquard means is present with a number of yarn feed
guides having a number of yarn feed openings for each of said
: gripping means to feed yarn ~ the desired colour to a gripperO
j 10 A further simplification is that only one series of adjoining
yarn supply guides is present feeding in turn yarn to the pairs
of grippersO
The jacquard means is characterized in that it comprises lifters
and two series of slidabl0 pins are present for each of the ad-
jacent lifters to which each thread-feed-guide is secured, said
; pins being arranged one below the other in which the distance be-
. tween the pins positioned one below the other of every series
corresponds with and is identical to the distance between the series
of two openings in the thread-feed-guidesO Said jacquard device
is further characterized in that each one of the two serie~ of
pins in each lifter are placed in turn in front of a single series
of horizontal needles, which presses out in a predetermined sense
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one of the pins of a series of the desired height, whereupon all
pins of the li~ters lying Q ide by side, which have ~een pressed
out at varying heights, are positioned at equal height so that
the connected yarn-feed-guides position two rows of differently
coloured yarns in front of a set of grippers in the sequence of
the desired colour-figurations~
Said jacquard means is only necessary if yarns are used being
` 10584~37
coloured during their manufacturingO In case a plurality of
differently coloured yarns has to be used it is preferred to
colour said yarns in a predetermined pattern of colours before
feeding them into the device described aboveO A yarn colouring
device performing this patterned colouring is characterized in
that it comprises a number of colouring devices for different
types of colour~ each of said colouring devices having two
identical and simultaneously rotating colouring rollers, the
surface of said rollers being provided with strips of foam material
provided in longitudinal direction of the rollers, and that in
such a way that the width of the strips of foam material is ~qual
to the distance between the strips on the rollers in such a manner
:' that the yarns may be coloured with sharply outlined short sections
of the same length, as well as with a continuous length for which
the two rollers are disposed in such a way that the space between
: two layers of foam material of one roller is overlapped by a
strip of foam material on the other rollerO Said device further
being characterized in that above the rollers a nu~ber of small
wheels is present to press the yarn to be coloured onto the foam
material provided with colouring substance of the roller when
the yarn has to be colouredO
Another type of yarn colouring device comprises a number
of injectors with needle valves to which colouring material may
be supplied of which injectors the housing may be moved up an,d
down according to a predetermined sequence and said needlevalves
are stationary.
In using this type of yarn colouring device each pile requires
only a single uncoloured yarn cone so that both rows of differently
: coloured threads needed for the manufacture of a carpet having
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a width of 5 metres require only 4,000 cones with uncoloured
yarnsO The method is very economical because the stock of
coloured yarns may be modest and, in addition, the length of all
thread ends may be printed in more colours according to the se-
quence of various figuration~0
A simple embodiment is obtained that is characterized in
that simultaneously two rows of yarns are coloured in different
colours according to the desired colour-figuration, and that the
two rows are fed to a single thread feed guide having two rows of
thread feed openings, said device offering in turn said two rows
of yarns simultaneously to one of the pairs of grippers of two
gripping and pressing devices positioned one below the other.
With the above described device each yarn end or yarn section
of a row of yarn ends lying side by side can be printed in longi-
tudinal direction at certain distances being the same in all yarn
ends of the row according to the sequence of entirely different
colour-figurations with differently coloured colouring substances,
so that the web con~tituted by joining two rows of yarn ends
~i~ having been coloured in this manner, does not only have a dif-
20 ferent arrangement of the various colour changes in the length of
the web, but also colour changes in the width of the web, said
- web being formed by the length of the yarn ends lying side by side,
according to the sequence of entirely different colour-
figurationsO
Another advantage of the device according to the invention
is that a large number of double carpet webs may be manufactured
simultaneously with a colour-figuration which may extend along
the entire width of the carpet, that is up to a width of 5 metres
or more and that the length of one figuration is unlimited O
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A further advantag~ is that eOg. forty webs consistinq of
two pile lengths connected to each other, are manufactured, the
pile layer of which is subsequently cut off so that at the same
time eighty pile carpet webs are manufactured O that at the
same time eighty loop-carpets are manufacturedO
Still another advantage of the unit is that eOgO eighty
carpet webs may be manufactured simultaneously~ all of them
having the same figurations but that it is also possible to make
eight lots of different figuration, each lot consisting of ten
carpet webs having the same colour-figurations in the pile
laye rs O
Still another advantage is that the two webs being manu-
: factured with mutually connected piles and after having been cut
in the centre of said pile layer, show colour-figurations in
the mirror-image of each other so that in laying said webs side
by side a colour-figuration is formed having a width of 10 metres,
which is very interesting for carpet-covering in a large room
Still another advantage is the high production ~ate of
carpet webs, carpets cut to size, carpet rugs or carpet squares
which may be manufactured with different figuration and in pile
or loop-layer at the same time, in which all steps of manufacture
; are carried out consecutively, iOeO without any conveyance of
manufactured carpet rolls for further treatmentO
The device and method accoraing to the invention will be dis-
cussed more in detail with reference to the embodiments illus~a-
ted in the accompanying drawings,~herein:
FigO 1 and 2 are a sectional view of the gripping means
: with a jacquard device, said device being positioned in turn in
front of one of the two pairs of grippers;
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FigO 3 illustrates the press in rest position;
FigO 3a illustrates the adjusted pressing elements in
operating position for a higher pile or loop heigh~;
FigO 4 is a front view of the gripper and the press means and
endless chains or V belts lying side by side, as well as a licker;
FigO 5 illustrates the structure of the suspension of the
elements of the press means lying side by side;
FigsO 5a, b and c show the extension mechanism; FigO 5a in
side elevation and FigsO 5b and c in not extended and extended
position respectively;
FigO 6 illustrates the structure of a gripper;
FigO 7 illustrates the conveyance of the pile websJ the
cutting device and the further transportation of the cut pile
strips;
~, FigO 8 is a sectional view of a colour-printing machine;
FigO 9 is a sectional view of a colouring machine;
FigO 9a is a plan view of the colouring machine;
FigO 10 is a sectional view of an endless belt with rips
between which the yarns to be coloured are kept and perforations
have been provided in the belt as a result of which superfluous
colouring matter i~ sucked out by vacuum;
FigO 11 and 12 illustrated a conveyor belt constituted by
compartments between which the yarns are clamped when being
fixed, washed and carried;
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Fig. 13 illu~trates the po~ition of the conveyor compart-
ment3 during the process of fixing;
Fig. 14 illustrates the wa~hing device and part of the
tunnel drier; this Fig. is a continuation of the right hand side of
Fig. 13;
Fig. 15 illustrates a yarn-feed device without jacquard
device being u ed when the yarns have been coloured in a large
number of different colours;
Fig. 16 (on the same sheet as Fig. 4) illustrates a pile
web manufactured according to the method; and Figs. 16a, b, and c
(on the same sheet) show different stages of the pile strips;
Fig. 17 (on the same sheet as Fig. 7) is a front view of
the vertically movable conveyor chain guides with tenter means;
Fig. 18 is a sectional view of a conveying means;
Fig. 18a shows the bottom side of a conveying means with
a pile strip gripped ~y the grippers;
Fig. 19 illustrates a gripper at its proper size of a
conveying means;
Fig. l9a, b and c (on the same sheet as Fig. 3) show the
operation of a gripper;
; Fig. 20 illustrates a carriage with twenty conveying means
and the carriage couplings;
Fig. 21a is a top view of the wheel tracks, Fig. 21b a
front view, and Fig. 21c a side view showing a stacking device
positioned therebelow;
Fig. 22 is a partly sectional front view of two stacking
devices lying side by side.
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In the device according to Fig. 1 and 2 tw~ identical
pairs gripping means have been arranged one below the other,
two grippers 5, 6 of which, a~ well as 7, 8 being connected
with each other and, thus operate simultaneously. Each set of
grippers can be moved by the fact that the plates 28 will run with
tongue and groove in plates 29, being secured to the machine
frame.
A press device 1, 2, 3, 4 is preæent above each gripper,
said device comprising pressing elements lying -~ide by side
and a number of endless V belts la, 2a, 3a and 4a running side
by side have been provided below the grippers.
Fig. 3 is a sectional view of the pressing elements lying
side by side, their length being equal to the width of the carpet
webs to be manufactured, e.g. 5 metres. The distances between
the pressing elements may be adjusted, depending on the desired
height of the pile of the carpet webs (Fig. 3A). The V belts
running side by side are also adjustable.
As illustrated in Fig. 3, 4 and 5 each pressing element
consists of pressure plates 19 laying side by side. As appears
from Fig. 5, the pressure plates are connected to spindles 16
being suspended in bearing blockq 17. Said blocks 17 may be
moved along spindles 18 secured to a frame 20.
Four bearings 21 are present on the press frame, said
bearings may be moved along 3hafts 22 in vertical direction.
The jaws 12 of the pressing elements and the V belts may
be adjusted by an extension mechanism as shown in Fig. Sa, Sb, 5c.
Fig. 6 illustrates the structure of a gripper. The jaws
12 of the grippers may be opened or closed mechanically
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or by means of air cylinders 130
When with this machine colour-figurations must be made with
at least three colours, then first of all uncoloured yarns are
. printed in three colours, which will be discussed later onO
The device is characterized in that two rows of differently
coloured pile yarns are offered alternately to one of the two sets
of grippers 5J 6 and 7, 8 hy the yarn-feed guides 24 lying ~ide
by side, of which the series of three rows of yarn feed openings
25, 26 lying above of each other are adjusted at variable heightO
In the upper part of the jacquard device 23 the holders 24
are connected to the same number of lifters 27 which may be moved
in vertical direction and which lie also ~ide by sideO The lifters
are characterized in that slidable pins 30 and 31 run through each
lifterJ said pins having been arranged in series one below the
otherO The number of pins of each lifter is equal to the number
; of openings in the yarn-feed guides 240 One of the series of pins ~:
30 or 31 in turn is brought at equal height in front of the hori-
zontal needles 32 by means of the beam 33 movable in vertical
directionO The jacquard card 34 in which the desired pattern is ~:
: 20 punched out brings one of the horizontal series of needles 32
via one of the series of vertical needle~ 35 in front of one of
the projections of the horizontally moving beam 36, so that said
needle is pressed outwards against one of the pins 30 or 31
respectivelyO
In this manner a pin of each lifter is forced out according
to the data of the jacquard cardO The up and down moving beam
:. 37 presses all pins forced out at different heights at an equal
level, so that the lifters are positioned at varying heights
and the yarn-feed guides 24 connected to the lifters are carried
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along also at varying heights~ so that said guides offer two
rows of differently coloured yarns lying side by side to one
of the sets of grippers 5, 6 and 7, 8 respectivelyO
When the colour-figurations must be composed of more than
three differently coloured yarns, colouring, fixation, washing and
drying techniques according to the invention are used, which de-
pend on the composition of the pile yarnsO
.
To that end, uncoloured woollen yarns 45, which easily absorb colou-
ring matter which, in addition, may contain substances added to
prevent shrinkage of the yarns, are guided freely between rollers
46 and presser rolls 47 lying above said rollers (see FigO 8)o
.: For each differently coloured matter 48 two troughs 49 and
50 are disposed side by side, wherein a colouring matter of the
same colaur is present and all troughs are identicalO
Rollers 46 rotate with the same circumferential speed in said
~roughs 49 as the speed of the yarns 45 advanced thereabove, said
rollers at their periphery being provided with ribs 51 of foam
material in the length-direction of said rollers. The recesses 52
thus formed between ribs 51 have the same width as the ribs,
20 e O go 8 cmO
A cylinder 53 rotates in the bath 48 of colouring material
and touches the foam material 51, said cylinder pressing the
colouring substance into the foam layer 51, while blades 54
remove any superfluous colouring matterO
The small presser rolls 47 lying side by side are present
on the periphery of a large cylinder 55 having the same
dimension as the periphery of the foam material 51 of the rollers
46 and said roll~ rotate with the same speed so that they are
moved with the same circumferential speedO
lOS84~7
At rest, the presser rolls are pushed free above the two yarns 45
running below said rolls by two pressure springs 56 and 57, said
springs pressing against the hinged arms 58 and 590
A plate 60 i8 present above arm 59~ said plate being re-
ciprocated in horizontal direction over supports 61 being hinged
at points 620
Pins have been provided side by side through the plate 60,
io e. at the same distances as the upper sides of the narrow
arms 590 Pins 63 are connected to electrical magnets 64 J being
disposed in series one behind the other for reasons of spaceO
When an electrical magnet 64 receives an impulse via a
: patterning device, the related pin 63 is pressed downwardsO When
the plate 60 is moved in horizontal direction, pin 63 pushes
against the upper side of arm 59 sO that presser roll 47 via arm
~ 58 is pre-~sed downwards over cylinder 55 onto the two yarns 45
`~ lying below said roll. The yarns-are pressed onto the foam
material 51 of rollers 46 and coloured over a distance being equal
to the width of the foam rib, iOeO 8 cm, whereupon the electric :~
contact of the magnet is interrupted and the presser roll is
pressed upwards by the pressure springs 56 and 570
Blades 65 clean the cylinder 55 and the colouring matter scraped
off i~ discharged in gutters 660
Both foam layers 51 of the ~ller 46 having been disposed
one behind the other in the troughs 49 and 50 overlap each
other, iOeO when one roller has coloured a range of 8 cm, the
. next roller may print the next range of 8 cmO In this way, the
yarns may be pxinted over a distance of 8 cm or a multiple
! thereof or continuously with the same colouring substanceO
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The yarns 45 rest on travellers 67, which are endless and
which are rinsed in water 68 after each contact with the yarnsO
For the colouring of yarns which are difficult in absorbing
colouring matter, a yarn-colouring device in accordance with
the invention is used in the present device(see FigO 9), said
yarn-colouring device comprising injectors 69 which are operated
according to a program in accordance with the sequence of the de-
sired figuration, in that the injectors have been connected to
electrical magnets or air cylinders 700
For every colouring substance the injectors 69 are staggered
in four rows lying one behind the other for reasons of space
(FigO 9a)0
The axes 71 of the magnets or air cylinders 70 are coupled
to the casings 72 of the injectors 69 and the valve needles 73
are fixed to the supporting frame 740
When a magnet or air cylinder 79 is energized the axis 71
i9 pulled downwards so that the casing 72 of the injector is
lowered and by the fact that the valve needle 73 stays at its
place, opening 72a i9 no longer barred by said needleO
The nozzle of the injector and opening 72a æe lowered onto
the underlying yarns which are kept at their place on the endless
belt between ridges 72b (see FigO lO)o Perforations 76 have been
provided in the endless belt, through which perforations the
superfluous colouring substance, if any, which is discharged by
the injectors, is sucked off by vacuum below the endless belt
after each process of colouringO
When the various colours have been applied onto the pile
yarns and the coloured yarns have been delivered, the endless
belt is conveyed through a rinsing basin 75b and brushed cleanO
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In order to prevent bleeding of ~;he differently coloured
colouring substances the yarns ~ay be provided with a reserving
agent at certain distances, having a width of 2 mmO This part
always comes in the latex paste on the backing so that said part
is invisible.
When the yarns have been coloured, the colouring substance
may be dried and the yarns may be processed to a finished product,
whereupon the colouring substances of said finished product must
be fixed, washed and driedO
Another method consists in that the printed yarns are fixed,
washed and dried and are then processed to a final productO Said
method has the advantage that the yarns dry faster than a carpet
web and that they have to be dried only onceO
For this reason the latter method will be discussedO ~ ;
The coloured yarns 86 are clamped between compartments 77
~ at certain distancesO A number of compartments 77 have been con- :
nected like chains (see FigO 11, 12)o The upper sides of the
cross members 78 between the links 79 lie at centre height of the
:~ points of rotation 80.
Rotatable pins have been provided in the partitions 78, the upper
side of said pins having been provided with a thin metal plate 810
. The lower side of the pins is bent to form an angle 80a, said pins
being connected by a strip 82, said strip being connected also with
a pin 83 being thickerO Said pin terminates with a cam in the
bearing 84 in which a helical shaped groove is providedO The pins
.:
: are pressed downwardsby pres~ure springs 80b, in which the metal
plates 81 with their sides abutting are pressed in the centre onto
partitions 780
When pins 83 an~ 80a are pressed upwards along guide 85,
; pin 83 will turn one quarter-turn so that all plates 81 will
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also turn open one quarter turn and in this manner the yarns may
be dispo~ed on the partitions or removed therefromO
As illustrated in FigO 12 the yarns 86 are in clamped
position on the partitions and they are, thus, fixed, wa~hed and
driedO
Wheels 87, 88 and 89 are present on the links 79, said wheels
run in three tracks 90, 91 and 92 respectively lying one below
the otherO
As illustrated in FigO 13 it is, thus, possible that during
the process of fixing of the yarn 86, the compartments 77 are ad-
vanced in almost vertical position in the fixation room 93 wherein
exhausters 94 provide a proper distribution of steamO
When the process of fixing has been completed, the yarns
. are washed and dried and also clamped in the compartments 77
.;~ (see FigO 14)o When the yarns have left the tunnel drier 95 they
,:'
;::. are cooled and the plates 81 are turned open and the yarns leave
the conveyor belt without any signs of shrinkageO
If shrinkage of the yarns is required they are disposed
with more clearance between the compartments 77 so that they shrink
~: 20 during the fixing and washing.
Inasmuch as the methods applied when using simple colour-
figuration, in which the yarns are coloured in plain colours and
are arranged by means of a jacquard deviceJ are equal to the methods
according to which a multicolour-figuration is made, said latter
method will be described in substanceO
Moreover, a licker 38 is present in front of every
gripper-press device, as illustrated in FigO 4, as a result of
which series of two yarns or strips 39 lying side by side
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may be provided with thermoplastic or latex pasteO
The series of two yarns or the strip~ 39 lie continuously
on the endless V belts la, 2a, 3a and 4a parallel and at a mutual
distance side by ~ide, said distance being equal to the double
pile height and/or one length of a complete pile loopO The
distances between the yarns or strip~ 39 can be adjustedO
As illustra ~d in FigO 1 and 15, the sets of grippers 5,
. 6 and 7, 8 are moved in turn towards the yarn-feed guides 24,
where they pull two rows of differently coloured pile yarns threads -
at the length desired of eOgO 80 times the pile length of the
carpet websO The length of pile yarns being pulled is slightly
longer after which the grippers are moved back slightly so that
~: the yarns are free of tensionO
The press means press the pile yarns onto the Lmpregnated
strips or threads 39 which ares~pplied continuously on the belts
la, 2a, 3a, 4a so that a multicoloured web 40 is formed, where-
upon the yarns are cut off along the feed device by circular
knives 140
: When the yarns have been cut off along the yarn-feed device
said yarn-feed devices are moved in front of the other set of
grippers and, again~ in the manner described above, in the other
.~ gripper-press device a new section of the pile-yarn web is added
:~,
to the endless, multicoloured web 40 manufactured beforehand,
said web having a length being equ~l to the width of the carpet
webs.
; During the time that one of the gripper-press devices of
~,
a set of gripper~ makes a new section of web 40, in the other
device of the other set of grippers, the endless multicoloured
pile yarn web, as well as the threads or strips provided with
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the paste and which are not cut off, are conveyed between V
belts 41, 42, 43, 44 running on top of each other and having
a length being equal to the width of the carpet web (see FigO 7)0
So, every 9 seconds two pile layers having a length of
5 metres are made, said layers having an overall width of 80
pile lengths and/or loop lengths and per hour 800 pile layers are
manufacturedO Since in a carpet eOgO 2000 piles lie side by
side in the width of a pile row of 5 metres, 800 pile rows, lying
side by side, constitute a total length of 2 metresO
So, the hourly production is 80 carpet webs of 2 running
metres having a width of 5 metres, which means in one hour 160
- running metres of carpet web having a width of 5 metres, corres-
ponding with 800 sqO metres of carpet an hourO
Irrespective of the number of colours with which the yarns
are printed or coloured, which number may be 10 different colours
or more, yarns are used always for two rows of yarn of only 4,000
yarn cones so that including the connected ~pare cones, a total
number of 8,000 cones with uncoloured yarns are requiredO
With the yarn-colouring devices according to the invention
it is possible that the yarns differ in colour every 8 cm accord-
ing to the sequence of other colour-figurations, so that
simultaneously ten lots of carpet strips can be manufactured with
different colour-figurations, each lot consisting of eight
carpet webs with identical colour-figurationsO
FigO 16 illustrates a pile web, the threads of which have
been coloured in longitudinal direction according to different
colour-figurationsO
As illustrated in FigO 7, the pile webs being manufactured
on the endless V belts la, 2a and 3a, 4a respectively are joined
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when the latex threads or ~trips of one of the webs have been
licked again by lickers lOl, disposed between the V belts 41 and
43-
When the pile layer must be composed of loops, each pileyarn web 40 is conveyed individually between V belts 41, 42, 43
and 44.
The endless belts convey the continuous multicoloured
webs 40 to a nu~ber of circular knives 96 (in the present Example
forty knives) disposed at equal distances one beside the other,
the mutual distances of which being ad~ustable according to tha
length of two piles of the carpet webs to be manufactured. Said
circular knives cut the webs in forty continuous strips, iOeO
exactly between every second thread or strip 390 These continuous
multicoioured strips are, thus, composed of differently coloured
yarn ends lying side by side and being arranged according to the
~ sequence of the desired colour-figurations, the length of said
yarn ends being equal to the length of two piles or one loop of
the carpet webs to be manufacturedO
FigO 16a is a sectional view of two pile layers 98 fasten-
ed onto each other,which are cut between the strips 39 (see figO
16b) and FigO 16c illu~trates a single pile end which iq folded
to a loopO
The V belts convey the pile strips 40 to a chain conveyor
102 (see Fig. 17), said conveyor being supported on a frame 103
which may be moved in vertical direction by the air cylinders
1040
Tenter means are present on the chains extending parallel
side by side and the pile strips supplied are clamped on said
tenter means. In Fig. l9b the tenter means are shown in open
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position and in Fig. l9c in closed position. Fig. l9a shows afront view.
The arms 99 of the tenter means 98 extend along guide means
100 whereby they can be opened or closed.
For the correct height, the chain track 102 is brought by
the air cylinders 104 in front of one of the conveyor V belts 41,
42, 43 and 44 and the desired length, e.g. 5 metres, is 3upplied
on the chains, whereupon the circular knive 108 cuts off the pile
strips lying side by side.
Above the chain track 102, above the forty pile strips 40
conveyor means 109 are present.
On each element, at the lower side, small grippers 110 are
present, said grippers gripping with pins 105 in the pile strips
40 and clamp said strips. The grippers 110 are connected to each
other by tension members 111 and owing to the plates 112 secured
thereto the opening and closing of the grippers 110 may take place
outside the pres~ element.
Fig. 18 is a sectional view of the element 109 and Fig. 19
illustrates a gripper 110 at natural size.
Twenty elements 109 lie side by side in a carriage frame
(see Fig. 20). Between the frame beams 106, constituting the
length of the carriages 131, iron beams 113 have been disposed,
over which and under which bearing blocks 114 have been provided.
Shafts 115 extend through the bearing blocks, said shafts being
secured to the conveying means 109~ as a result of which the means
109 can be moved in vertical direction. Two catches 116 keep
the means 109 in upward position. The hinging structures 117
- are connected with each other by tension bar 118 so that the long
conveying means 109 cannot bend.
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'- AS illustrated in Fig. 18, the lower side of the conveying
means 109 is constituted by two sheets 119 and grippers 110 are
secured at the outer side thereto.
Said grippers 110 take the pile strip if a cut pile-carpet
~- has to be manufactured (Fig. 18a).
A pressure plate 120 i5 provided between the two sheet~ 119,
~ said plate may be moved vertically by the means 121 and pressure
- springs 122 have been disposed at the lower side of the sheets 119.When a carpet has to be manufactured, the pile layer of
which has been composed of loops, then the pile strips are pressed
in the form of loops over the entire length between the sheets 119.
The pressure springs 122 hold the loop strips. When the conveying
- means 109 has reached its destination, the loop-shaped yarn strip
is forced out from between the sheets by the pressure plate 120
and the loop rows are pressed into the latex layer of a backing.
When the forty pile strips have been disposed on the forty
chain conveyors 102, said strips being clamped on the tenter means,
the frame 103 is pushed upwards by the air cylinders 104 so that
the forty pile strips 40 are pæessed against the forty elements.
When the carpet web must have an open pile layer, air
cylinder 124 releases the catch 125 and air cylinder 126 moves
plate 112 90 that the connected tension member 111 closes all
grippers 110 and the pins 105 are rotated between the yarn end
portions of the pile strip 40 so that said strip . . . . . . .
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is pressed against the lower side of the element lOg.
When the carpet web is manufactured with loops, bars 123
press the pile strip lying between the chains between the two
sheets 119 of the conveying mean~ 109 in the form of a row of
loops which i6 held by pressure springs 122.
The elements 109 lie in series of twenty in a number of
carriages 131 running on rails (see Fig. 20), said carriages
are only coupled at 131a to each other at the inner side of
the track.
The carriages 131 are arranged in a certain number and in a
certain track, as appears ~rom a top view in Fig. 21a and a ront
view in Fig. 21b, and the stacking device 130 is disposed there-
under a~ seen in Fig. 21c.
When the forty conveying elements 109 have taken over
the forty pile strips 40 from the chain tracks 102, all
carriages 131 are moved over a length equal to the width of two
carriages 131 and another two carriages 131 i5 positioned above
the forty chain tracks, the forty conveying elements 109 o~ the
; latter carriages 131 being empty.
As appears from Fig. 21c, below each row o carriages 131
are ten stacking devices 130, 80 in total forty stacking device~
130 are provided.
Each time when two carriages 131 are moved, each carriage
131 delivers a pile strip 40 to the stacking device 130 disposed
thereunder and this i8 done always in the same sequence, i.e. ~he
first two carriages 131 always deliver the first two pile strips
40 to the first two stacking devices 130, the second two carriages
131 always the second pile strips 40 to the second two stacking
devices 130, etc.
When manufacturing loop-pile-carpets, always four loop
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rows are delivered by the first two carriages 131 in the
aforementioned sequence.
Fig. 22 is a partly sectional front view showing a
stacking device 130, said device being composed of two rolls 132 and
133 being adjustable. The rolls have the same length as the width
of the carpet web to be manufactured, i.e. for example 5 metres.
Endless belts 134, 135 are present on the rolls 132, 133,
said belts running over rolls 136, 137, 138 and the tension rolls
139.
Roll 140 and the roll 141 of the adjacent stacking
device in directions opposite to each other and the two
endless belts 135 and 145 run between said rolls and two
backing layers 142, 143 for the carpet webs to be made are
moved between said rolls.
Above the two backing layers 142 and 143 lying on the
endless belts 135 and 145 a stock of paste 144 is present so
that the bladeq 146 apply a layer of paste onto the backing
layers during their conveyance.
The backing layers provided with paste are carried along
by the conveyor belts 134, 135, 145 over rollers 132 and 133~
The conveying elemsnt 109 lying above is lowered and
delivers its pile strip 40 composed of two pile layers between
the two backing layers 142, 143.
When the conveying element 109 has been raised, the press
arms 147, which may be rotated, hit the newly arranged pile
row 40, said row, with both side edges on which the adhered
threads 39 are present, lying against the latex layers on
the backing layers.
The press arms 147 move slightly through the latex paste
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of the backing layers 142, 143 before they contact the pile
strip 40 and in this way they take along a small portion of the
paste which is supplied to the threads 39 of the pile strip 40
during the process of pressing downwards, with the result that
a portion of paste is provided on the connections of the pile
strip 40, into whLch layer the next pile strip 40 is adhered.
In this way, adhesion of the pile strips 40 take~ place
at the lower side and at the side edges of the strips 40, whereby
an efficient adhesion is obtained.
When a new pile strip 40 has been provided, the endless
belts 134, 135, 145 are moved over the desired distance.
When the latex has dried between the backing layers 142, 143
and the pile strips 40 and, consequently, the piles are adhered
to the backing 142, 143 a knife 148 cuts the piles of the web
along a width of the web into two carpet webs having a width of
5 metres in which the desired colour-figurations have been
provided.
. .
Moving an element 109 (Fig. 17) in vertical direction above
a stacking device 130 takes place in that air cylinders 149 rise
slightly and the holders 150 are pressed against the projections
151. Air cylinder~ 152 press the catches 116 away from below the
element 109 so that air cylinders 149 may be lowered with the
element. The shafts 115 of the element slide through the
bearings 114.
When an element 109 has been disposed between the backing
layers 142, 143 in a stacking device 130, air cylinder 153
presses catch 125 out of the hole 125b for the closed position
and 125a for the open position, and air cylinder 154 presses
against the plate 112 so that all grippers 110 are opened.
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When a looped-pile carpet i9 manufactured, a pile strip 40 (Fig.
16b) is present between the two sheets 119 of every conveying means,
the yarns of said pile row being bent into loops.
Rolls 132 and 133 are positioned at a distance being equal
to the distance of the lower sides of two conveying elements.
The two elements 109 are lowered simultaneously until the
highest point of the two rolls 132 and 133 and at the same time
two strips of pile loops are placed in the late~ layer of the
two backing layers 142, 143 which are present on the endless
belts 134 and 135.
The pressure plate 120 presses aside the loop-strip between
the sheets 119 and presses the strip of pile-loops into the
latex layer of the backing layers.
The backing layers 142, 143 provided in this way with pile
loops are subsequently guided between said rollers. The pressing
arms 147 and also the cutting means are not uYed here.
Since in this way 80 carpet webs are manufactured ~imultan-
eously, said webs may differ in two kinds of yarn and also in two
pile heights or loop lengths or a loop and pile layers may be
manufactured simultaneously in the carpet webs, while 8 lots of
different colour-figurations may be made at the same time, which
takes place with an hourly production of 80 x 2 metres of a carpet
web having a width of 5 metres, corresponding with an hourly
production of 800 sq. metres of carpet, 80 rolls of carpet webs
should be moved all at the same tLme. For this reason, the
rolling-up devices 149 (Fig. 21c) have been disposed in such a
way, taking into account a length of 2 metres being manufactured
in one hour, that always, due to adjustment of the distance of the
rolling-up region, e.g. every 10 minutes only one roll of carpet
having a length of 48 metres has been fully wound.
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